Kohler KG6208 Naturally Aspirated, KG6208TA Turbocharged Propane, Liquefied Petroleum Gas (LPG), Natural Gas (NG) Fueled Service Manual (tp7097)
These KG6208 and KG6208TA engines usually live on standby or prime-power generator sets, sitting in plant rooms, rooftops, or outdoor enclosures and kicking in when the grid drops or loads spike. This service manual is what I’d pull when I need to trace a misfire or power loss on propane or natural gas and prove whether the problem is ignition, fuel control, or a mechanical issue before ordering parts. For example, if the turbocharged unit is struggling to pick up load, this book walks you through checks so you can isolate whether it’s air, fuel, or timing instead of just throwing a new turbo or mixer at it.
Applications & Use Cases
- Verify ignition and fuel-system faults step by step before replacing coils, plugs, or regulators.
- Trace hard-start or no-start complaints on LPG/NG units using logical diagnostic sequences.
- Follow disassembly and reassembly procedures so components go back aligned, sealed, and torqued correctly.
- Use the manual to confirm sensor or actuator failures with tests instead of guessing.
- Support turbocharged KG6208TA troubleshooting, from air leaks to control-linkage adjustments.
FAQ
Q: Can I keep this manual on a tablet in the genset room?
A: Yes, it’s practical to use digitally; you can zoom diagrams and search text while you work beside the unit.
Q: Is it worth printing sections of this manual?
A: Many techs print the pages for a job, mark test results and measurements, then file them with the work order.
Safety Note
Always shut down, isolate fuel and electrical sources, and verify zero energy before opening or adjusting these engines.
📘 Show Index
Kohler KG6208 Naturally Aspirated, KG6208TA Turbocharged Propane, Liquefied Petroleum Gas (LPG), Natural Gas (NG) Fueled Index:
- Safety Precautions and Instructions
- Introduction
- Service Assistance
- Section 1. Fuel System Overview
- 1.1 Introduction
- 1.2 Air Fuel Mixer
- 1.3 Wastegate Control Solenoid (KG6208TAHD, Turbocharged Engines Only)
- 1.4 Charge Air Cooler (KG6208TASD and KG6208TAHD,Turbocharged Engines Only)
- 1.5 Coolant Temperature Sensor
- 1.6 Crankshaft Position (CKP) Sensor
- 1.7 Direct Acting Electronic Pressure Regulator
- 1.8 Electronic Control Module
- 1.9 Heated Exhaust Gas Oxygen (HEGO) Sensor
- 1.10 Ignition System
- 1.11 Oil Pressure Sender
- 1.12 Oil Separator (KG6208TAHD, Turbocharged Engines Only)
- 1.13 Throttle Body
- 1.14 Throttle Inlet Pressure (TIP) Sensor (KG6208TASD and KG6208TAHD, Turbocharged Engines Only)
- 1.15 TMAP Sensor
- 1.16 Throttle Position (TP) Sensor
- 1.17 Turbocharger (KG6208TASD and KG6208TAHD, Turbocharged Engines Only)
- 1.18 Turbocharger Oil Lines (KG6208TASD and KG6208TAHD, Turbocharged Engines Only)
- Section 2. Diagnostic Software and Troubleshooting Tests
- Section 3. Diagnostic Troubleshooting Codes
- 3.1 Safety Precautions
- 3.2 Powering the ECM On and Off
- 3.3 DTC to SPN/FMI Cross Reference
- 3.4 DTC Descriptions & Diagnostic Information
- 3.5 DTC 7 – Lockoff Short to Power
- 3.5.1 DTC 7 – Lockoff Short to Power (Trouble Tree)
- 3.6 DTC 16 – Crank and/or Cam Could Not Synchronize During Start
- 3.7 DTC 31 – HEGO/UEGO Heater Open / Ground Short
- 3.7.1 DTC 31 – HEGO/Uego Heater Open / Ground Short (Trouble Tree)
- 3.8 DTC 32 – HEGO/UEGO Heater Short to Power
- 3.8.1 DTC 32 – HEGO/Uego Heater Short to Power (Trouble Tree)
- 3.9 DTC 107 – MAP Low Voltage
- 3.9.1 DTC 107 – MAP Low Voltage (Trouble Tree)
- 3.10 DTC 108 – MAP High Pressure
- 3.10.1 DTC 108 – MAP High Pressure (Trouble Tree)
- 3.11 DTC 111 – IAT Higher Than Expected Stage 1
- 3.12 DTC 112 – IAT Low Voltage
- 3.12.1 DTC 112 – IAT Low Voltage (Trouble Tree)
- 3.13 DTC 113 – IAT High Voltage
- 3.13.1 DTC 113 – IAT High Voltage (Trouble Tree)
- 3.14 DTC 116 – ECT Higher Than Expected (Stage 1)
- 3.15 DTC 117 – ECT / CHT Low Voltage
- 3.15.1 DTC 117 – ECT / CHT Low Voltage (Trouble Tree)
- 3.16 DTC 118 – ECT / CHT High Voltage
- 3.16.1 DTC 118 – ECT / CHT High Voltage (Trouble Tree)
- 3.17 DTC 121 – TPS1 % Lower Than TPS2 %
- 3.17.1 DTC 121 – TPS1 % Lower Than TPS2 % (Trouble Tree)
- 3.18 DTC 122 – TPS1 Signal Voltage Low
- 3.18.1 DTC 122 – TPS1 Signal Voltage Low (Trouble Tree)
- 3.19 DTC 123 – TPS1 Signal Voltage High
- 3.19.1 DTC 123 – TPS1 High Voltage (Trouble Tree)
- 3.20 DTC 127 – IAT Higher Than Expected Stage 2
- 3.21 DTC 129 – BP Low Pressure
- 3.21.1 DTC 129 – BP Low Pressure (Trouble Tree)
- 3.22 DTC 134 – EGO1 (HEGO) Open / Lazy (HO2S1)
- 3.22.1 DTC 134 – EGO1 Open / Lazy (HO2S1) (Trouble Tree)
- 3.23 DTC 187 – FT Gaseous Fuel Extremely Low
- 3.24 DTC 217 – ECT Higher Than Expected 2
- 3.25 DTC 219 – RPM Higher Than Max Allowed Governed Speed
- 3.26 DTC 221 – TPS1 % Higher Than TPS2 %
- 3.26.1 DTC 221 – TPS1 % Higher Than TPS2 %, (Trouble Tree)
- 3.27 DTC 222 – TPS2 Signal Voltage Low
- 3.27.1 DTC 222 – TPS2 Signal Voltage Low (Trouble Tree)
- 3.28 DTC 223 – TPS2 Signal Voltage High
- 3.28.1 DTC 223 – TPS2 Signal Voltage High
- 3.29 DTC 336 – Crank Input Signal Noise
- 3.29.1 DTC 336 – Crank Input Signal Noise (Trouble Tree)
- 3.30 DTC 337 – Loss of Crankshaft Signal
- 3.30.1 DTC 337 – Loss of Crankshaft Signal (Diagnostic Aids)
- 3.31 DTC 341 – Cam Input Signal Noise
- 3.31.1 DTC 341 – Cam Input Signal Noise (Trouble Tree)
- 3.32 DTC 342 – Loss of Camshaft Input Signal
- 3.32.1 DTC 342 – Loss of Camshaft Input Signal (Diagnostic Aids)
- 3.33 DTC 520 – Oil Pressure Low Stage 1 (Sender)
- 3.34 DTC 521 – Oil Pressure High (Sender)
- 3.34.1 DTC 521 – Oil Pressure High (Sender) (Trouble Tree)
- 3.35 DTC 522 – Oil Pressure Sender Low Voltage
- 3.35.1 DTC 522 – Oil Pressure Sender Low Voltage (Trouble Tree)
- 3.36 DTC 523 – Oil Pressure Sender High Voltage
- 3.36.1 DTC 523 – Oil Pressure Sender High Voltage (Trouble Tree)
- 3.37 DTC 524 – Oil Pressure Low Stage 2 (Sender)
- 3.37.1 DTC 524 – Oil Pressure Low (Sender) (Trouble Tree)
- 3.38 DTC 562 – Battery Voltage (VBat) Low
- 3.38.1 DTC 562 – Battery Voltage (VBat) Low (Trouble Tree)
- 3.39 DTC 563 – Battery Voltage (VBat) High
- 3.39.1 DTC 563 – Battery Voltage (VBat) High (Trouble Tree)
- 3.40 DTC 601 – Microprocessor Failure – FLASH
- 3.40.1 DTC 601 – Microprocessor Failure – Flash (Trouble Tree)
- 3.41 DTC 604 – Microprocessor Failure – RAM
- 3.41.1 DTC 604 – Microprocessor Failure – RAM (Trouble Tree)
- 3.42 DTC 606 – Microprocessor Failure – COP
- 3.42.1 DTC 606 – Microprocessor Failure – COP (Trouble Tree)
- 3.43 DTC 615 – Start Relay Coil Open
- 3.43.1 DTC 615 – Start Relay Coil Open (Trouble Tree)
- 3.44 DTC 616 – Start Relay Control Ground Short
- 3.44.1 DTC 616 – Start Relay Control Ground Short (Trouble Tree)
- 3.45 DTC 642 – Sensor Supply Voltage 1 Low (5Vext1)
- 3.45.1 DTC 642 – Sensor Supply Voltage 1 Low (5VEXT1) (Trouble Tree)
- 3.46 DTC 643 – Sensor Supply Voltage 1 High (5Vext1)
- 3.46.1 DTC 643- Sensor Supply Voltage 1 High (5VEXT1) (Trouble Tree)
- 3.47 DTC 652 – Sensor Supply Voltage 2 Low (5Vext2)
- 3.47.1 DTC 652 – Sensor Supply Voltage 2 Low (5VEXT2) (Trouble Tree)
- 3.48 DTC 653 – Sensor Supply Voltage 2 High (5Vext2)
- 3.48.1 DTC 653- Sensor Supply Voltage 2 High (5VEXT2) (Trouble Tree)
- 3.49 DTC 685 – Relay Coil Open
- 3.49.1 DTC 685 – Relay Coil Open (Trouble Tree)
- 3.50 DTC 686 – Relay Control Ground Short
- 3.50.1 DTC 686 – Relay Coil Ground Short (Trouble Tree)
- 3.51 DTC 687 – Relay Coil Short to Power
- 3.51.1 DTC 687 – Relay Coil Short to Power (Trouble Tree)
- 3.52 DTC 1089 (359) – Fuel Runout Longer Than Expected
- 3.53 DTC 1111- RPM Above Fuel Rev Limit Level
- 3.53.1 DTC 1111- RPM Above Fuel Rev Limit Level (Diagnostic Aids)
- 3.54 DTC 1112- RPM Above Spark Rev Limit Level
- 3.54.1 DTC 1112- RPM Above Spark Rev Limit Level (Diagnostic Aids)
- 3.55 DTC 1113 – Fuel Runout Longer Than Expected
- 3.56 DTC 1151 – Closed Loop High (LPG)
- 3.57 DTC 1152 – Closed Loop Low (LPG)
- 3.58 DTC 1153 – Closed Loop High Natural Gas
- 3.59 DTC 1154 – Closed Loop Low Natural Gas
- 3.60 DTC 1161 – Aadaptive Learn High (LPG)
- 3.61 DTC 1162 – Adaptive Learn Low (LPG)
- 3.62 DTC 1163 – Adaptive Learn High (Natural Gas)
- 3.63 DTC 1164 – Adaptive Learn Low (Natural Gas)
- 3.64 DTC 1171 – EPR / CFV Regulation Pressure Higher Than Expected
- 3.64.1 DTC 1171 – EPR / CFV Regulation Pressure Higher Than Expected (Trouble Tree)
- 3.65 DTC 1172 – EPR / CFV Regulation Pressure Lower Than Expected
- 3.65.1 DTC 1172 – EPR / CFV Regulation Pressure Lower Than Expected (Trouble Tree)
- 3.66 DTC 1173 – EPR / CFV Comm Lost
- 3.66.1 DTC 1173 – EPR / CFV Comm Lost (Schematic)
- 3.66.2 DTC 1173 – EPR / CFV Comm Lost (Trouble Tree)
- 3.67 DTC 1174 – EPR / CFV voltage supply high
- 3.68 DTC 1175 – EPR / CFV Voltage Supply Low
- 3.69 DTC 1176 – EPR / CFV Internal Actuator Fault Detection
- 3.70 DTC 1177 – EPR / CFV Internal Circuitry Fault Detection
- 3.71 DTC 1178 – EPR / CFV Internal Comm Fault Detection
- 3.72 DTC 1179 – CFV Flow Higher Than Commanded
- 3.72.1 DTC 1179 CFV Flow Higher Than Commanded (Trouble Tree)
- 3.73 DTC 1180 – CFV Flow Lower Than Commanded
- 3.73.1 DTC 1180 CFV Flow Lower Than Commanded (Trouble Tree)
- 3.74 DTC 1311 – DTC 1318 – Misfire Detected (Cylinder 1-8)
- 3.74.1 DTC 1311 – Misfire Detected (Cylinder 1-8) (Diagnostic Aids)
- 3.75 DTC 1325 – Knock Retard at Limit
- 3.76 DTC 1351 – DTC 1358 – Spark Plug or Coil Failure (Cylinders 1-8)
- 3.77 DTC 1611 – Sensor Supply Voltage (5Vext 1/2) Simultaneous Out-of-Range
- 3.77.1 DTC 1611 – Sensor Supply Voltage (5VEXT 1/2) Simultaneous Out-Of-Range , (Trouble Tree)
- 3.78 DTC 1612 – Microprocessor Failure – RTI 1
- 3.79 DTC 1613 – Microprocessor Failure – RTI 2
- 3.79.1 DTC 1613 – Microprocessor Failure – RTI 2 (Trouble Tree)
- 3.80 DTC 1614 – Microprocessor Failure – RTI 3
- 3.80.1 DTC 1614 – Microprocessor Failure – RTI 3 (Trouble Tree)
- 3.81 DTC 1615- Microprocessor Failure – A/D
- 3.81.1 DTC 1615 – Microprocessor Failure – A/D (Trouble Tree)
- 3.82 DTC 1616 – Microprocessor Failure – Interrupt
- 3.82.1 DTC 1616 – Microprocessor Failure – Interrupt (Trouble Tree)
- 3.83 DTC 1626 – CAN1 J1939 Transmit (Tx) Fault
- 3.84 DTC 1627 – J1939 Receive (Rx) Fault
- 3.85 DTC 1628 – CAN1 Address Conflict Failure
- 3.86 DTC 1629 – J1939 TSC1 Message Receipt Loss
- 3.86.1 DTC 1628 – CAN1 Address Conflict Failure (Trouble Tree)
- 3.87 DTC 1635 – PWM3 Open / Ground Short
- 3.87.1 DTC 1635 – PWM3 Open / Ground Short (Trouble Tree), Duty-Cycle PWM Type
- 3.87.2 DTC 1635 – PWM3 Open / Ground Short (Trouble Tree), Resistance Simulation Type
- 3.88 DTC 1636 – PWM3 Short to Power
- 3.88.1 DTC 1636 – PWM3 Short to Power (Trouble Tree), Duty-Cycle PWM Type
- 3.88.2 DTC 1636 – PWM3 Short to Power (Trouble Tree), Resistance Simulation Type
- 3.89 DTC 1644 – MIL Control Ground Short
- 3.89.1 DTC 1644 – MIL Control Ground Short (Trouble Tree)
- 3.90 DTC 1645 – MIL Control Short to Power
- 3.90.1 DTC 1645 – MIL Control Short to Power (Trouble Tree)
- 3.91 DTC 1673 – Calibration Configuration Error
- 3.92 DTC 1674 – Hardware ID Failure
- 3.92.1 DTC 1674 – Hardware ID Failure (Trouble Tree)
- 3.93 DTC 2111 – Unable to Reach Lower TPS
- 3.93.1 DTC 2111 – UNABLE TO REACH LOWER TPS (Trouble Tree)
- 3.94 DTC 2112 – Unable to Reach Higher TPS
- 3.95 DTC 2135 – Simultaneous Voltages Out of Range
- 3.96 DTC 2229 – BP High Pressure
- 3.97 DTC 2300,2303,2306,2309,2312,2315,2318,2321 – Primary Loop Open or Low-Side Short to Ground (Curr. Meas. Reqd) (Cylinder 1-8)
- 3.97.1 DTC 2300 – Primary Loop Open or Low-Side Short to Ground (Trouble Tree)
- 3.98 DTC 2301,2304,2307,2310,2313,2316,2319,2321 – Primary Coil Shorted (Current Measurement Required) (Cylinder 1-8)
- 3.98.1 DTC 2301 – Primary Coil Shorted (Trouble Tree)
- Appendix A. Torque Specifications
- Appendix B. Abbreviations
Kohler
